Crystallized glass compositions for coating oxide-based ceramics

ABSTRACT

The present invention relates to a zinc oxide varistor as a characteristic element of an arrestor for protecting a transmission and distribution line and peripheral devices thereof from surge voltage created by lightning, and more particularly a highly reliable zinc oxide varistor excellent in the non-linearity with respect to voltage, the discharge withstand current rating properties, and the life characteristics under voltage, a method of preparing the same, and PbO type crystallized glass for coating oxide ceramics employed for a zinc oxide varistor, etc. A zinc oxide varistor of the present invention comprises a sintered body (1) and a high resistive side layer (3) consisting of crystallized glass with high crystallinity containing the prescribed amount of SiO 2 , MoO 3 , WO 3 , TiO 2 , NiO, etc., formed on the sides of the sintered body (1) to enhance the strength and the insulating property thereof, thereby improving the non-linearity with respect to voltage, the discharge withstand current rating properties and the life characteristics under voltage. The crystallized glass composition for coating of the present invention comprises PbO as a main component and additives such as ZnO, B 2  O 3 , SiO 2 , MoO 3 , WO 3 , TiO 2 , and NiO to enhance the crystallinity and the insulating property thereof.

CROSS REFERENCE TO RELATED APPLICATIONS

This is a continuation application of application Ser. No. 08/147,182filed , Nov. 1, 1993, now U.S. Pat. No. 5,447,892, which is a divisional application of application Ser. No. 07/689,948 filed Jun. 26, 1991, now U.S. Pat. No. 5,294,908.

TECHNICAL FIELD

The present invention particularly relates to a zinc oxide varistor used in the field of an electric power system, a method of preparing the same, and a crystallized glass composition used for coating an oxide ceramic employed for a thermistor or a varistor.

BACKGROUND ART

A zinc oxide varistor comprising ZnO as a main component and several kinds of metallic oxides including Bi₂ O₃, CoO, Sb₂ O₃, Cr₂ O₃, and MnO₂ as other components has a high resistance to surge voltage and excellent non-linearity with respect to voltage. Therefore, it has been generally known that the zinc oxide varistor is widely used as an element for a gapless arrestor in place of conventional silicon carbide varistors in recent years.

For example, Japanese Laid-open Patent Publication No. 62-101002, etc., disclose conventional methods of preparing a zinc oxide varistor. The aforesaid prior art reference discloses as follows: first, to ZnO as a main component are added metallic oxides such as Bi₂ O₃, Sb₂ O₃, Cr₂ O₃, CoO, and MnO₂ each in an amount of 0.01 to 6.0 mol % to prepare a mixed powder. Then, the mixed powder thus obtained is blended and granulated. The resulting granules are molded by application of pressure in a cylindrical form, after which the molded body is baked in an electric furnace at 1200° C. for 6 hours. Next, to the sides of the sintered body thus obtained are applied glass paste consisting of 80 percent by weight of PbO type frit glass containing 60 percent by weight of PbO, 20 percent by weight of feldspar, and an organic binder by means of a screen printing machine in a ratio of 5 to 500 mg/cm² followed by baking treatment Next both end faces of the element thus obtained are subjected to surface polishing and then an aluminum metallikon electrode is formed thereon, thereby obtaining a zinc oxide varistor.

However, since a zinc oxide varistor prepared by the aforesaid conventional method employed screen printing, a high resistive side layer was formed with a uniform thickness. This led to an advantage in that discharge withstand current rating properties did not largely vary among varistors thus prepared, whereas since the high resistive side layer was made of composite glass consisting of PbO type frit glass and feldspar, the varistor also had disadvantages as follows: the discharge withstand current rating properties were poor, and the non-linearity with respect to voltage lowered during baking treatment of glass, thereby degrading the life characteristics under voltage.

DISCLOSURE OF INVENTION

The present invention overcomes the above conventional deficiencies. The objectives of the present invention are to provide a zinc oxide varistor with high reliability and a method of preparing the same. Another objective of the present invention is to provide a crystallized glass composition suited for coating an oxide ceramic employed for a varistor or a thermistor.

In the present invention, for the purpose of achieving the aforesaid objectives, to the sides of a sintered body comprising ZnO as a main component is applied crystallized glass comprising PbO as a main component such as PbO--ZnO--B₂ O₃ --SiO₂, MoO₃, WoO₃, NiO, Fe₂ O₃, or TiO₂ type crystallized glass, followed by baking treatment, to form a high resistive side layer consisting of PbO type crystallized glass on the sintered body, thereby completing a zinc oxide varistor.

Furthermore, the present invention proposes a crystallized glass composition for coating an oxide ceramic comprising PbO as a main component, and other components such as ZnO, B₂ O₃, SiO₂, MoO₃, WO₃, NiO, Fe₂ O₃, and TiO₂.

Since crystallized glass comprising PbO as a main component according to the present invention has high strength of the coating film due to the addition

of SiO₂, MoO₃, WO₃, NiO, Fe₂ O₃, TiO₂, etc., and excellent adhesion to a sintered body, it has excellent discharge withstand current rating properties and high insulating properties. This results in a minimum decline in non-linearity with respect to voltage during baking treatment to obtain a highly reliable zinc oxide varistor with excellent life characteristics under voltage.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows across-sectional view of a zinc oxide varistor prepared by using PbO type crystallized glass according to the present invention.

BEST MODE FOR CARRYING OUT THE INVENTION

A zinc oxide varistor, a method of preparing the same, and a crystallized glass composition for coating according to the present invention will now be explained in detail by reference to the following examples.

EXAMPLE 1

First, to a ZnO powder were added 0.5 mol % of Bi₂ O₃, 0.5 mol % of Co₂ O₃, 0.5 mol % of MnO₂, 1.0 mol of Sb₂ O₃, 0.5 mol % of Cr₂ O₃, 0.5 mol % of NiO, and 0.5 mol % of SiO₂ based on the total amount of the mixed powder. The resulting mixed powder was sufficiently blended and ground together with pure water, a binder, and a dispersing agent, for example, in a ball mill, after which the ground powder thus obtained was dried and granulated by means of a spray dryer to prepare a powder. Next, the resulting powder was subjected to compression molding to obtain a molded powder with a diameter of 40 mm and a thickness of 30 mm, followed by degreasing treatment at 900° C. for 5 hours. Thereafter, the resulting molded body was baked at 1150° C. for 5 hours to obtain a sintered body.

Alternatively, as for crystallized glass for coating, each predetermined amount of PbO, ZnO, B₂ O₃, and SiO₂ was weighed, and then mixed and ground, for example, An a ball mill, after which the ground powder was melted at a temperature of 1100° C. and rapidly cooled in a platinum crucible to be vitrified. The resulting glass was subjected to coarse grinding, followed by fine grinding in a ball mill to obtain frit glass. On the other hand, as a control sample, composite glass consisting of 80.0 percent by weight of frit glass consisting of 70.0 percent by weight of PbO, 25.0 percent by weight of ZnO, and 5.0 percent by weight of B₂ O₃, and 20.0 percent by weight of feldspar (feldspar is a solid solution comprising KAlSi₃ O₈, NaAlSi₃ O₈, and CaAl₂ Si₂ O₈) was prepared in the same process as described before. The composition, the glass transition point Tg, the coefficient of linear expansion α, and the crystallinity of the frit glass prepared in the aforesaid manner are shown in Table 1 below.

The glass transition point Tg and the coefficient of linear expansion u shown in Table 1 were measured by means of a thermal analysis apparatus. As for the crystallinity, the conditions of glass surface were observed by means of a metallurgical microscope or an electron microscope, after which a sample with high crystallinity was denoted by a mark "602", a sample with low crystallinity a mark "66", and a sample with no=crystal a mark "×".

                  TABLE 1                                                          ______________________________________                                               Composition               α                                        Name  (Percent by weight)                                                                               Tg     (10.sup.-7 /                                                                         Crystal-                                 of glass                                                                             PbO     ZnO    B.sub.2 O.sub.3                                                                      SiO.sub.2                                                                            (°C.)                                                                        °C.)                                                                          linity                             ______________________________________                                          G101*                                                                               40      25     10    25    470  61    ◯                      G102  50      25     10    15    456  68    ◯                      G103  60      15     10    15    432  79    ◯                      G104  75      15      5    10    385  85    ◯                       G105*                                                                               80       5      5    10    380  93    X                                   G106*                                                                               60      10      5    25    363  70    ◯                      G107  60      15      5    20    375  66    ◯                      G108  60      29      5     6    404  72    ◯                       G109*                                                                               60      35     15     0    409  69    ◯                       G110*                                                                               65      25       2.5   7.5 351  73    ◯                      G111    62.5  25      5      7.5 388  75    ◯                      G112    57.5  25     10      7.5 380  70    ◯                       G113*                                                                                 52.5  25     15      7.5 427  66    X                                   G114*                                                                               66      20     10     4    350  79    ◯                      G115  64      20     10     6    374  75    ◯                      G116  60      20     10    10    396  70    ◯                      G117  55      20     10    15    402  66    ◯                       G118*                                                                               50      20     10    20    448  59    X                                  ______________________________________                                          A mark "*" denotes a control sample which is not within the scope of the       present invention.                                                       

As shown in Table 1, the addition of a large amount of PbO raises the coefficient of linear expansion α, while the addition of a large amount of ZnO lowers the glass transition point Tg, which facilitates crystallization of the glass composition. Conversely, the addition of a large amount of B₂ O₃ raises the glass transition point, and the addition of more than 15.0 percent by weight of B₂ O₃ causes difficulty in crystallization of the glass composition. Further, with an increase in the amount of SiO₂ added, the glass transition point tends to increase, while the coefficient of linear expansion tends to decrease.

Next, 85 percent by weight of the frit glass of the aforementioned sample and 15 percent by weight of a mixture of ethyl cellulose and butyl carbitol acetate as an organic binder were sufficiently mixed, for example, by a triple roll mill, to obtain glass paste for coating. The glass paste for coating thus obtained was printed on the sides of the aforesaid sintered body by means of, for example, a screen printing machine for curved surface with a screen of 125 to 250 mesh. In this process, the amount of the glass paste for coating to be applied was determined by measurement of a difference in weight between the sintered bodies prior and posterior to a process for coating with paste and drying for 30 minutes at 150° C. The amount of the glass paste for coating to be applied was also adjusted by adding an organic binder and n-butyl acetate thereto. Thereafter, the glass paste for coating was subjected to baking treatment at temperatures in the range of 350° to 700° C. to form a high resistive side layer on the sides of the sintered body. Next, the both end faces of the sintered body were subjected to surface polishing, and then an aluminum metallikon electrode was formed thereon, thereby obtaining a zinc oxide varistor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a cross-sectional view of a zinc oxide varistor obtained in the aforesaid manner according to the present invention. In FIG. 1, the reference numeral 1 denotes a sintered body comprising zinc oxide as a main component, 2 an electrode formed on both end faces of the sintered body 1, and 3 a high resistive side layer obtained by a process for baking crystallized glass on the sides of the sintered body 1.

Next, the appearance, V_(1mA) /V₁₀μA, the discharge withstand current rating properties, and the life characteristics under voltage of a zinc oxide varistor prepared by using the glass for coating shown in Table 1 above are shown in Table 2 below. The viscosity of the glass paste for coating was controlled so that the paste could be applied in a ratio of 50 mg/cm². The baking treatment was conducted at a temperature of 550° C. for 1 hour. Each lot has 5 samples. V_(1mA) /V₁₀μA was measured by using a DC constant-current source. The discharge withstand current rating properties were examined by applying an impulse current of 4/10 μS to each sample at five-minute intervals in the same direction twice and stepping up the current from 40 kA. Then, whether any unusual appearance was observed or not was examined visually, or, if necessary, by means of a metallurgical microscope. In the Table, the mark "∘" denotes that no unusual appearance was observed in a sample after the prescribed electric current was applied to the sample twice. The mark "Δ" and "×" denote that unusual appearance was observed in 1 to 2 samples, and 3 to 5 samples, respectively. Further, with the life characteristics under voltage, the time required for leakage current to reach 5 mA, i.e., a peak value was measured at ambient temperature of 130° C. and a rate of applying voltage of 95% (AC, peak value). V_(1mA) /V₁₀μA and the life characteristics under voltage are represented by an average of those of samples.

The number of samples, the method of measuring V_(1mA) /V₁₀μA, the method of testing the discharge withstand current rating, and the method of evaluating the life characteristics under voltage described above will be adopted unchanged in each following examples unless otherwise stated.

                                      TABLE 2                                      __________________________________________________________________________                          Life under                                                                           Discharge withstand current                         Name of              voltage                                                                              rating properties                                   glass  Appearance                                                                            V.sub.1 mA /V.sub.10 μA                                                            (Time)                                                                               40 kA                                                                              50 kA                                                                              60 kA                                                                              70 kA                                                                              80 kA                               __________________________________________________________________________      G101* Partially                                                                             1.15   185   X   --  --  --  --                                         peel off                                                                G102   Good   1.21   206   ◯                                                                      ◯                                                                      ◯                                                                      X   --                                  G103   Good   1.23   370   ◯                                                                      ◯                                                                      ◯                                                                      Δ                                                                            X                                   G104   Good   1.34   320   ◯                                                                      ◯                                                                      Δ                                                                            X   --                                   G105* Crack  1.19    96   X   --  --  --  --                                  G106   Porous 1.16   340   Δ                                                                            X   --  --  --                                  G107   Good   1.18   314   ◯                                                                      ◯                                                                      ◯                                                                      X   --                                  G108   Good   1.25   291   ◯                                                                      ◯                                                                      X   --  --                                   G109* Good   1.38   158   ◯                                                                      X   --  --  --                                   G110* Good   1.20   369   ◯                                                                      ◯                                                                      X   --  --                                  G111   Good   1.21   351   ◯                                                                      ◯                                                                      Δ                                                                            X   --                                  G112   Good   1.19   332   ◯                                                                      ◯                                                                      ◯                                                                      X   --                                   G113* Porous 1.18   345   Δ                                                                            X   --  --  --                                   G114* Good   1.34   171   ◯                                                                      ◯                                                                      X   --  --                                  G115   Good   1.25   243   ◯                                                                      ◯                                                                      ◯                                                                      ◯                                                                      X                                   G116   Good   1.21   297   ◯                                                                      ◯                                                                      ◯                                                                      ◯                                                                      Δ                             G117   Good   1.19   495   ◯                                                                      ◯                                                                      ◯                                                                      X   --                                   G118* Peel off                                                                              1.17   331   X   --  --  --  --                                  Conventional                                                                          Good   1.26   153   ◯                                                                      Δ                                                                            X   --  --                                  example                                                                        __________________________________________________________________________      A mark "*" denotes a control sample which is not with in the scope of the      present invention.                                                       

The data shown in Tables 1 and 2 indicated that when the coefficient of linear expansion of glass for coating was smaller than 65×10⁻⁷ /°C. G101, G118 glass), the glass tended to peel off, and when exceeding 90×10⁻⁷ /°C., the glass tended to crack. It is also confirmed that the samples of glass which cracked or peeled off have poor discharge withstand current rating properties due to the inferior insulating properties of the high resistive side layer. However, even if the coefficient of linear expansion of glass for coating is within the range of 65×10⁻⁷ to 90×10⁻⁷ /°C., glass with poor crystallinity (G105, G113 glass) tends to crack and also has poor discharge withstand current rating properties. This may be attributed to the fact that the coating film of crystallized glass has lower strength than that of noncrystal glass. The addition of ZnO as a component of crystallized glass is useful for the improvement of the physical properties, especially, a decrease in the glass transition point of glass without largely affecting the various electric characteristics and the reliability of a zinc oxide varistor. It is also confirmed that when conventional composite glass consisting of PbO--ZnO--B₂ O₃ glass and feldspar, i.e., a control sample, is used, the life characteristics under voltage is at a practical level, while the discharge withstand current rating properties are poor.

The amount of SiO₂ added will now be considered. First, any composition with less than 6.0 percent by weight of SiO₂ added has inferior life characteristics under voltage. This may be attributed to the fact that the addition of less than 6.0 percent by weight of SiO₂ lowers the insulation resistance of the coating film. On the other hand, the addition of more than 15.0 percent by weight of SiO₂ lowers the discharge withstand current rating properties. This may be attributed to the fact that glass tends to become porous due to its poor fluidity during the baking process. Consequently, a crystallized glass composition comprising PbO as a main component for the high resistive side layer of a zinc oxide varistor is required to comprise SiO₂ at least in an amount of 6.0 to 15.0 percent by weight.

The above results confirmed that the most preferable crystallized glass composition for coating comprised 50.0 to 75.0 percent by weight of PbO, 10.0 to 30.0 percent by weight of ZnO, 5.0 to 10.0 percent by weight of B₂ O₃, and 6.0 to 15.0 percent by weight of SiO₂. A crystallized glass composition for the high resistive side layer of a zinc oxide varistor is also required to have coefficients of linear expansion in the range of 65×10⁻⁷ to 90×10⁻⁷ /°C.

Next, by the use of G111 glass shown as a sample of the present invention in Table 1, the amount of glass paste to be applied was examined. The results are shown in Table 3 below. Glass paste was applied in a ratio of 1.0 to 300.0 mg/cm² which was controlled by the viscosity and the number of application of the paste. As shown in Table 3, when glass paste is applied in a ratio of less than 10.0 mg/cm² the resulting coating film has low strength, while with a ratio of more than 150.0 mg/cm² glass tends to have pinholes. Both cases result in poor discharge withstand current rating properties. These results confirmed that glass paste was applied most preferably in a ratio of 10.0 to 150.0 mg/cm².

                                      TABLE 3                                      __________________________________________________________________________         Amount of           Life under                                                                           Discharge withstand current                      Sample                                                                             application         voltage                                                                              rating properties                                No. (mg/cm.sup.2)                                                                        Appearance                                                                            V.sub.1 mA /V.sub.10 μA                                                            (Time)                                                                               40 kA                                                                              50 kA                                                                              60 kA                                                                              70 kA                                                                              80 kA                            __________________________________________________________________________     101*                                                                                1    Good   1.14   367   X   --  --  --  --                               102*                                                                                3    Good   1.15   354   Δ                                                                            X   --  --  --                               103*                                                                                5    Good   1.20   360   Δ                                                                            X   --  --  --                               104 10    Good   1.23   394   ◯                                                                      ◯                                                                      Δ                                                                            X   --                               105 50    Good   1.21   351   ◯                                                                      ◯                                                                      Δ                                                                            X   --                               106 150   Good   1.28   308   ◯                                                                      ◯                                                                      ◯                                                                      Δ                                                                            X                                107*                                                                               200   Partially                                                                             1.33   269   ◯                                                                      X   --  --  --                                         flow                                                                 108*                                                                               300   Flow   1.30   245   X   --  --  --  --                               __________________________________________________________________________      A mark "*" denotes a control sample which is not within the scope of the       present invention.                                                       

Next, by the use of G111 glass shown as a sample of the present invention in Table 1, the conditions under which glass paste was subjected to baking treatment were examined. The results are shown in Table 4 below. The viscosity of glass paste was controlled so that the glass paste may be applied in a ratio of 50.0 mg/cm². Glass paste was subjected to baking treatment at temperatures in the range of 350° to 700° C. for 1 hour in air. Apparent from Table 4, when baking treatment was conducted at a temperature of less than 450° C., glass was not sufficiently melted, resulting in poor discharge withstand current rating properties. On the other hand, when baking treatment was conducted at a temperature of more than 650° C., the voltage ratio markedly lowered, resulting in poor life characteristics under voltage. These results indicated that glass paste was subjected to baking treatment most preferably at temperatures in the range of 450° to 650° C. It was also confirmed that the baking treatment conducted for 10 minutes or more had no serious effect on various characteristics.

                                      TABLE 4                                      __________________________________________________________________________         Temperature          Life under                                                                           Discharge withstand current                     Sample                                                                             of baking            voltage                                                                              rating properties                               No. (°C.)                                                                          Appearance                                                                            V.sub.1 mA /V.sub.10 μA                                                            (Time)                                                                               40 kA                                                                              50 kA                                                                              60 kA                                                                              70 kA                                                                              80 kA                           __________________________________________________________________________     111*                                                                               350    Not    1.08    51   X   --  --  --  --                                         sintered                                                            112*                                                                               400    Porous 1.12    77   Δ                                                                            X   --  --  --                              113 450    Good   1.24   224   ◯                                                                      ◯                                                                      Δ                                                                            X   --                              114 500    Good   1.21   365   ◯                                                                      ◯                                                                      Δ                                                                            X   --                              115 600    Good   1.33   408   ◯                                                                      ◯                                                                      ◯                                                                      Δ                                                                            X                               116 650    Good   1.40   215   ◯                                                                      ◯                                                                      ◯                                                                      X   --                              117*                                                                               700    Partially                                                                             1.79    19   ◯                                                                      X   --  --  --                                         flow                                                                __________________________________________________________________________      A mark "*" denotes a control sample which is not with in the scope of the      present invention.                                                       

EXAMPLE 2

Crystallized glass comprising PbO as a main component which contains MoO₃, and a zinc oxide varistor using the same as a material constituting a high resistive side layer will now be explained.

First, each predetermined amount of PbO, ZnO, B₂ O₃, SiO₂ , and MoO₃ was weighed, and then crystallized glass for coating was prepared according to the same process as that used in Example 1 described before. The results are shown in Table 5 below.

                                      TABLE 5                                      __________________________________________________________________________     Name of                                                                             Composition (Percent by weight)                                                                    Tg α                                                                              Crystal-                                     glass                                                                               PbO  ZnO B.sub.2 O.sub.3                                                                   SiO.sub.2                                                                          MoO.sub.3                                                                          (°C.)                                                                      (10.sup.-7 /°C.)                                                              linity                                       __________________________________________________________________________      G201*                                                                              40   25   5 10  20  349                                                                               61    ◯                                G202 50   25   5 10  10  355                                                                               75    ◯                                G203 75   10   5  5  5   336                                                                               88    ◯                                 G204*                                                                              85   10   5  0  0   315                                                                               96    X                                             G205*                                                                              55   40   5  0  0   350                                                                               60    ◯                                G206 55   30  10  0  5   355                                                                               67    ◯                                G207 70    5  15  5  5   366                                                                               75    Δ                                       G208*                                                                              70    0  20  5  5   375                                                                               87    X                                            G209   67.5                                                                              20  10  0    2.5                                                                              378                                                                               79    ◯                                G210   67.4                                                                              20  10   0.1                                                                                2.5                                                                              382                                                                               80    ◯                                G211   62.5                                                                              20  10  5    2.5                                                                              388                                                                               75    ◯                                G212   57.5                                                                              20  10 10    2.5                                                                              400                                                                               73    ◯                                 G213*                                                                                47.5                                                                              20  10 20    2.5                                                                              405                                                                               68    ◯                                 G214*                                                                                59.99                                                                             20  10 10    0.01                                                                             395                                                                               70    ◯                                G215   59.9                                                                              20  10 10    0.1                                                                              398                                                                               69    ◯                                G216 55   20  10 10  5   404                                                                               72    ◯                                G217 50   20  10 10  10  405                                                                               68    ◯                                 G218*                                                                              45   20  10 10  15  410                                                                               62    ◯                                __________________________________________________________________________      A mark "*" denotes a control sample which is not within the scope of the       present invention.                                                       

As shown in Table 5, the addition of a large amount of PbO raises the coefficient of linear expansion (α), while the addition of a large amount of ZnO lowers the glass transition point (Tg), which facilitates crystallization of the glass composition. Conversely, the addition of a large amount of B₂ O₃ raises the glass transition point, and the addition of more than 15.0 percent by weight of B₂ O₃ causes difficulty in crystallization of the glass composition. Further, with an increase in the amount of SiO₂ added, the glass transition point tends to increase, while the coefficient of linear expansion tends to decrease. With an increase in the amount of MoO₃ added, the crystallization of glass proceeded. The glass composition comprising a small amount of PbO and B₂ O₃ tended to become porous.

Next, the aforesaid frit glass was made into paste, after which the resulting glass paste was applied to the sides of the sintered body of Example 1, followed by baking treatment to prepare a sample of a zinc oxide varistor in the same process as that used in the above example. Thereafter, the resulting samples were evaluated for their characteristics.

The results are shown in Table 6 below.

                                      TABLE 6                                      __________________________________________________________________________                                Discharge withstand current                         Name of              Life under                                                                           rating properties                                   glass  Appearance                                                                            V.sub.1 mA /V.sub.10 μA                                                            voltage                                                                              40 kA                                                                              50 kA                                                                              60 kA                                                                              70 kA                                                                              80 kA                               __________________________________________________________________________      G201* Peel off                                                                              1.16   352   X   --  --  --  --                                  G202   Good   1.17   450   ◯                                                                      ◯                                                                      ◯                                                                      X   --                                  G203   Good   1.23   381   ◯                                                                      ◯                                                                      Δ                                                                            X   --                                   G204* Crack  1.55    15   X   --  --  --  --                                   G205* Partially                                                                             1.31   181   Δ                                                                            X   --  --  --                                         peel off                                                                G206   Good   1.20   319   ◯                                                                      ◯                                                                      ◯                                                                      Δ                                                                            X                                   G207   Good   1.19   485   ◯                                                                      ◯                                                                      X   --  --                                   G208* Partially                                                                             1.31   238   X   --  --  --  --                                         crack                                                                   G209   Good   1.29   256   ◯                                                                      X   --  --  --                                  G210   Good   1.28   363   ◯                                                                      ◯                                                                      Δ                                                                            X   --                                  G211   Good   1.23   472   ◯                                                                      ◯                                                                      ◯                                                                      X   --                                  G212   Good   1.20   550   ◯                                                                      ◯                                                                      X   --  --                                   G213* Porous 1.18   316   X   --  --  --  --                                   G214* Good   1.34   230   Δ                                                                            X   --  --  --                                  G215   Good   1.17   434   ◯                                                                      ◯                                                                      X   --  --                                  G216   Good   1.15   890   ◯                                                                      ◯                                                                      ◯                                                                      ◯                                                                      X                                   G217   Good   1.13   950   ◯                                                                      ◯                                                                      ◯                                                                      X   --                                   G218* Porous 1.21   241   X   --  --  --  --                                  Conventional                                                                          Good   1.26   153   ◯                                                                      Δ                                                                            X   --  --                                  example                                                                        __________________________________________________________________________      A mark "*" denotes a control sample which is not within the scope of the       present invention.                                                       

The data shown in Tables 5 and 6 indicated that when the coefficient of linear expansion of glass for coating was smaller than 65×10⁻⁷ /°C. (G201, G205, G218 glass), the glass tended to peel off, and when exceeding 90×10⁻⁷ /°C. (G204 glass), the glass tended to crack. It is supposed that the samples of glass which cracked or peeled off have poor discharge withstand current rating properties due to the inferior insulating properties of the high resistive side layer. However, even if the coefficient of linear expansion of glass for coating is within the range of 65×10⁻⁷ to 90×10⁻⁷ /°C., glass with poor crystallinity (G208 glass) tends to crack and also has poor discharge withstand current rating properties. This may be attributed to the fact that the coating film of crystallized glass has higher strength than that of noncrystal glass.

The amount of MoO₃ added will now be considered. First, any composition with 0.1 percent by weight or more of MoO₃ added has improved non-linearity with respect to voltage, accompanied by the improved life characteristics under voltage. This may be attributed to the fact that the addition of 0.1 percent by weight or more of MoO₃ raises the insulation resistance of the coating film. On the other hand, the addition of more than 10.0 percent by weight of MoO₃ lowers the discharge withstand current rating properties. This may be attributed to the fact that glass tends to become porous due to its poor fluidity during baking process. Consequently, a PbO--ZnO--B₂ O₃ --SiO₂ --MoO₃ type crystallized glass composition for the high resistive side layer of a zinc oxide varistor is required to comprise MoO₃ at least in an amount of 0.1 to 10.0 percent by weight.

The above results confirmed that the most preferable crystallized glass composition for coating comprised 50.0 to 75.0 percent by weight of PbO, 10.0 to 30.0 percent by weight of ZnO, 5.0 to 10.0 percent by weight of B₂ O₃, 0 to 15.0 percent by weight of SiO₂, and 0.1 to 10.0 percent by weight of MoO₃. The crystallized glass composition for the high resistive side layer of a zinc oxide varistor is also required to have coefficients of linear expansion in the range of 65×10⁻⁷ to 90×10⁻⁷ /°C.

Next, by the use of G206 glass shown as a sample of the present invention in Table 5, the amount of glass paste to be applied was examined. The results are shown in Table 7 below. Glass paste was applied in a ratio of 1.0 to 300.0 mg/cm² which was controlled by the viscosity and the number of application of the paste. As shown in Table 7, when glass paste is applied in a ratio of less than 10.0 mg/cm² the resulting coating film has low strength, while with a ratio of more than 150.0 mg/cm² glass tends to flow or have pinholes. Both cases result in poor discharge withstand current rating properties. These results indicated that glass paste was applied most preferably in a ratio of 10.0 to 150.0 mg/cm².

                                      TABLE 7                                      __________________________________________________________________________         Amount of           Life under                                                                           Discharge withstand current                      Sample                                                                             application         voltage                                                                              rating properties                                No. (mg/cm.sup.2)                                                                        Appearance                                                                            V.sub.1 mA /V.sub.10 μA                                                            (Time)                                                                               40 kA                                                                              50 kA                                                                              60 kA                                                                              70 kA                                                                              80 kA                            __________________________________________________________________________     201*                                                                                1    Good   1.10   318   X   --  --  --  --                               202*                                                                                5    Good   1.13   364   Δ                                                                            X   --  --  --                               203 10    Good   1.14   913   ◯                                                                      ◯                                                                      ◯                                                                      X   --                               204 50    Good   1.15   890   ◯                                                                      ◯                                                                      ◯                                                                      ◯                                                                      X                                205 150   Good   1.20   592   ◯                                                                      ◯                                                                      ◯                                                                      Δ                                                                            X                                206*                                                                               200   Partially                                                                             1.29   387   ◯                                                                      X   --  --  --                                         flow                                                                 207*                                                                               300   Flow   1.30   311   X   --  --  --  --                               __________________________________________________________________________      A mark "*" denotes a control sample which is not within the scope of the       present invention.                                                       

Next, by the use of G206 glass shown as a sample of the present invention in Table 5, the conditions under which glass paste was subjected to baking treatment were examined. The results are shown in Table 8 below. The viscosity of glass paste was controlled so that the glass paste may be applied in a ratio of 50.0 mg/cm². Glass paste was subjected to baking treatment at temperatures in the range of 350° to 700° C. for 1 hour in air. As a result, when baking treatment was conducted at a temperature of less than 450° C., glass paste was not sufficiently melted, resulting in poor discharge withstand current rating properties. On the other hand, when baking treatment was conducted at a temperature of more than 650° C., the voltage ratio markedly lowered, resulting in poor life characteristics under voltage. These results indicated that glass paste was subjected to baking treatment most preferably at temperatures in the range of 450° to 650° C.

                                      TABLE 8                                      __________________________________________________________________________         Temperature          Life under                                                                           Discharge withstand current                     Sample                                                                             of baking            voltage                                                                              rating properties                               No. (°C.)                                                                          Appearance                                                                            V.sub.1 mA /V.sub.10 μA                                                            (Time)                                                                               40 kA                                                                              50 kA                                                                              60 kA                                                                              70 kA                                                                              80 kA                           __________________________________________________________________________      211*                                                                              350    Not    1.12    48   X   --  --  --  --                                         Sintered                                                             212*                                                                              400    Porous 1.13    52   X   --  --  --  --                              213 450    Good   1.15   431   ◯                                                                      ◯                                                                      X   --  --                              214 500    Good   1.15   980   ◯                                                                      ◯                                                                      ◯                                                                      Δ                                                                            X                               215 600    Good   1.22   850   ◯                                                                      ◯                                                                      ◯                                                                      Δ                                                                            X                               216 650    Good   1.32   452   ◯                                                                      ◯                                                                      X   --  --                               217*                                                                              700    Flow   1.76    5    X   --  --  --  --                              __________________________________________________________________________      A mark "*" denotes a control sample which is not within the scope of the       present invention.                                                       

EXAMPLE 3

Crystallized glass comprising PbO as a main component which contains WO₃, and a zinc oxide varistor using the same as a material constituting a high resistive side layer will now be explained.

First, each predetermined amount of PbO, ZnO, B₂ O₃, SiO₂, and MoO₃ was weighed, and then crystallized glass for coating was prepared according to the same process as that used in Example 1 described before. The crystallized glass thus obtained was evaluated for the glass transition point (Tg), the coefficient of linear expansion (α), and the crystallinity. The results are shown in Table 9 below.

                                      TABLE 9                                      __________________________________________________________________________     Name of                                                                             Composition (percent by weight)                                                                    Tg α                                                                              Crystal-                                     glass                                                                               PbO  ZnO B.sub.2 O.sub.3                                                                   SiO.sub.2                                                                          WO.sub.3                                                                           (°C.)                                                                      (10.sup.-7 /°C.)                                                              linity                                       __________________________________________________________________________      G301*                                                                              40   25   5 10  20  355                                                                               60    ◯                                G302 50   25   5 10  10  361                                                                               73    ◯                                G303 75   10   5  5  5   340                                                                               89    ◯                                 G304*                                                                              85   10   5  0  0   315                                                                               96    X                                             G305*                                                                              50   40   5  5  0   342                                                                               62    ◯                                G306 50   30  10  5  5   351                                                                               66    ◯                                G307 65    5  15  5  5   372                                                                               73    X                                             G308*                                                                              70    0  20  5  5   384                                                                               88    X                                             G309*                                                                                67.4                                                                              20  10   0.1                                                                                2.5                                                                              380                                                                               81    ◯                                G310   67.0                                                                              20  10   0.5                                                                                2.5                                                                              384                                                                               80    ◯                                G311   62.5                                                                              20  10  5    2.5                                                                              392                                                                               76    ◯                                G312   57.5                                                                              20  10 10    2.5                                                                              401                                                                               72    ◯                                 G313*                                                                                47.5                                                                              20  10 20    2.5                                                                              406                                                                               67    ◯                                 G314*                                                                                59.9                                                                              20  10 10    0.1                                                                              396                                                                               71    ◯                                G315   59.5                                                                              20  10 10    0.5                                                                              399                                                                               72    ◯                                G316 55   20  10 10  5   404                                                                               70    ◯                                G317 50   20  10 10  10  405                                                                               68    ◯                                 G318*                                                                              45   20  10 10  15  412                                                                               66    ◯                                __________________________________________________________________________      A mark "*" denotes a control sample which is not within the scope of the       present invention.                                                       

As shown in Table 9, the addition of a large amount of PbO raises the coefficient of linear expansion, while the addition of a large amount of ZnO lowers the glass transition point (Tg), which facilitates crystallization of the glass composition. Conversely, the addition of a large Mount of B₂ O₃ raises the glass transition point, and the addition of more than 15.0 percent by weight of B₂ O₃ causes difficulty in crystallization of the glass composition. Further, with an increase in the Mount of SiO₂ added, the glass transition point tends to increase, while the coefficient of linear expansion tends to decrease. With an increase in the amount of WO₃ added, the crystallization of glass proceeded.

Next, the aforesaid frit glass was made into paste, after which the resulting glass paste was applied to the sides of the sintered body of Example 1, followed by baking treatment to prepare a sample of a zinc oxide varistor in the same process as that used in Example 1 above. Thereafter, the resulting samples were evaluated for their characteristics.

The results are shown in Table 10 below.

                                      TABLE 10                                     __________________________________________________________________________                          Life under                                                                           Discharge withstand current                         Name of              voltage                                                                              rating properties                                   glass  Appearance                                                                            V.sub.1 mA /V.sub.10 μA                                                            (Time)                                                                               40 kA                                                                              50 kA                                                                              60 kA                                                                              70 kA                                                                              80 kA                               __________________________________________________________________________      G301* peel off                                                                              1.19   346   X   --  --  --  --                                  G302   Good   1.20   400   ◯                                                                      ◯                                                                      Δ                                                                            X   --                                  G303   Good   1.30   292   ◯                                                                      ◯                                                                      ◯                                                                      X   --                                   G304* Crack  1.55    15   X   --  --  --  --                                   G305* Partially                                                                             1.36   142   X   --  --  --  --                                         Peel off                                                                G306   Good   1.24   280   ◯                                                                      ◯                                                                      ◯                                                                      Δ                                                                            X                                   G307   Good   1.21   397   ◯                                                                      Δ                                                                            X   --  --                                   G308* Partially                                                                             1.34   221   X   --  --  --  --                                         crack                                                                    G309* Good   1.31   260   ◯                                                                      X   --  --  --                                  G310   Good   1.29   334   ◯                                                                      ◯                                                                      Δ                                                                            X   --                                  G311   Good   1.25   415   ◯                                                                      ◯                                                                      ◯                                                                      X   --                                  G312   Good   1.22   490   ◯                                                                      ◯                                                                      X   --  --                                   G313* Porous 1.18   345   X   --  --  --  --                                   G314* Good   1.35   247   ◯                                                                      X   --  --  --                                  G315   Good   1.29   330   ◯                                                                      ◯                                                                      X   --  --                                  G316   Good   1.18   451   ◯                                                                      ◯                                                                      ◯                                                                      Δ                                                                            X                                   G317   Good   1.15   600   ◯                                                                      ◯                                                                      Δ                                                                            X   --                                   G318* Porous 1.20   298   X   --  --  --  --                                  Conventional                                                                          Good   1.26   153   ◯                                                                      Δ                                                                            X   --  --                                  example                                                                        __________________________________________________________________________      A mark "*" denotes a control sample which is not within the scope of the       present invention.                                                       

The data shown in Tables 9 and 10 indicated that when the coefficient of linear expansion of glass for coating was smaller than 65×10⁻⁷ /°C. (G301, G305 glass), the glass tended to peel off, and when exceeding 90×10⁻⁷ /°C., the glass tended to crack. It is supposed that the samples of glass which cracked or peeled off have poor discharge withstand current rating properties due to the inferior insulating properties of the high resistive side layer. However, even if the coefficient of linear expansion of glass for coating is within the range of 65×10⁻⁷ to 90×10⁻⁷ /°C., glass with poor crystallinity (G304, G308 glass) tends to crack and also has poor discharge withstand current rating properties. This may be attributed to the fact that the coating film of crystallized glass has lower strength than that of noncrystal glass.

The amount of WO₃ added will now be considered. First, any composition with 0.5 percent by weight or more of WO₃ added has the improved non-linearity with respect to voltage, accompanied by the improved life characteristics under voltage. This may be attributed to the fact that the addition of 0.5 percent by weight or more of WO₃ raises the insulation resistance of the coating film. On the other hand, the addition of more than 10.0 percent by weight of WO₃ (G1glass) lowers the discharge withstand current rating properties. This may be attributed to the fact that glass tends to become porous due to its poor fluidity during baking process. Consequently, a crystallized glass composition comprising PbO as a main component for the high resistive side layer of a zinc oxide varistor is required to comprise WO₃ at least in an amount of 0.5 to 10.0 percent by weight.

The above results confirmed that the most preferable crystallized glass composition comprised 50.0 to 75.0 percent by weight of PbO, 10.0 to 30.0 percent by weight of ZnO, 5.0 to 15.0 percent by weight of B₂ O₃, 0.5 to 15.0 percent by weight of SiO₂, and 0.5 to 10.0 percent by weight of WO₃. A crystallized glass composition for the high resistive side layer of a zinc oxide varistor is also required to have coefficients of linear expansion in the range of 65×10⁻⁷ /°C. to 90×10⁻⁷ /°C.

Next, by the use of G316 glass shown as a sample of the present invention in Table 9, the amount of glass paste to be applied was examined. The results are shown in Table 11 below. Glass paste was applied in a ratio of 1.0 to 300.0 mg/cm² which was controlled by the viscosity and the number of application of the paste. As shown in Table 11, when glass paste is applied in a ratio of less than 10.0 mg/cm² the resulting coating film has low strength, while with a ratio of more than 150.0 mg/cm² glass tends to have pinholes. Both cases result in poor discharge withstand current rating properties. These results indicated that glass paste was applied most preferably in a ratio of 10.0 to 150.0 mg/cm².

                                      TABLE 11                                     __________________________________________________________________________         Amount of           Life under                                                                           Discharge withstand current                      Sample                                                                             application         voltage                                                                              rating properties                                No. (mg/cm.sup.2)                                                                        Appearance                                                                            V.sub.1 mA /V.sub.10 μA                                                            (Time)                                                                               40 kA                                                                              50 kA                                                                              60 kA                                                                              70 kA                                                                              80 kA                            __________________________________________________________________________     301*                                                                                1    Good   1.11   309   X   --  --  --  --                               302*                                                                                5    Good   1.13   362   Δ                                                                            X   --  --  --                               303 10    Good   1.14   578   ◯                                                                      ◯                                                                      Δ                                                                            X   --                               304 50    Good   1.18   451   ◯                                                                      ◯                                                                      ◯                                                                      Δ                                                                            X                                305 150   Good   1.21   490   ◯                                                                      ◯                                                                      ◯                                                                      ◯                                                                      X                                306*                                                                               200   Partially                                                                             1.28   300   ◯                                                                      X   --  --  --                                         flow                                                                 307*                                                                               300   Flow   1.31   241   Δ                                                                            X   --  --  --                               __________________________________________________________________________      A mark "*" denotes a control sample which is not within the scope of the       present invention.                                                       

Next, by the use of G316 glass shown as a sample of the present invention in Table 9, the conditions under which glass paste was subjected to baking treatment were examined. The results are shown in Table 12 below. The viscosity and the number of application of glass paste were controlled so that the glass paste may be applied in a ratio of 50.0 mg/cm². Glass paste was subjected to baking treatment at temperatures in the range of 350° to 700° C. for 1 hour in air. Apparent from Table 12, when baking treatment was conducted at a temperature of less than 450° C., glass paste was not sufficiently melted, resulting in poor discharge withstand current rating properties. On the other hand, when baking treatment was conducted at a temperature of more than 600° C., the voltage ratio markedly lowered, resulting in poor life characteristics under voltage. These results indicated that glass paste was subjected to baking treatment most preferably at temperatures in the range of 450° to 600° C.

                                      TABLE 12                                     __________________________________________________________________________         Temperature          Life under                                                                           Discharge withstand current                     Sample                                                                             of baking            voltage                                                                              rating properties                               No. (°C.)                                                                          Appearance                                                                            V.sub.1 mA /V.sub.10 μA                                                            (Time)                                                                               40 kA                                                                              50 kA                                                                              60 kA                                                                              70 kA                                                                              80 kA                           __________________________________________________________________________     311*                                                                               350    Not    1.10    45   X   --  --  --  --                                         sintered                                                            312*                                                                               400    Porous 1.12    42   X   --  --  --  --                              313 450    Good   1.15   230   ◯                                                                      ◯                                                                      X   --  --                              314 500    Good   1.16   547   ◯                                                                      ◯                                                                      ◯                                                                      X   --                              315 600    Good   1.21   608   ◯                                                                      ◯                                                                      ◯                                                                      Δ                                                                            X                               316*                                                                               650    Partially                                                                             1.39   211   ◯                                                                      X   --  --  --                                         flow                                                                317*                                                                               700    Partially                                                                             1.65    8    X   --  --  --  --                                         flow                                                                __________________________________________________________________________      A mark "*" denotes a control sample which is not within the scope of the       present invention.                                                       

EXAMPLE 4

Crystallized glass comprising PbO as a main component which contains TiO₂, and a zinc oxide varistor using the same as a material constituting a high resistive side layer will now be explained.

First, each predetermined amount of PbO, ZnO, B₂ O₃, SiO₂, and TiO₂ was weighed, and than crystallized glass for coating was prepared according to the same process as that used in Example 1 above. The crystallized glass thus obtained was evaluated for the glass transition point (Tg), the coefficient of linear expansion (α), and the crystallinity. The results are shown in Table 13 below.

                                      TABLE 13                                     __________________________________________________________________________     Name of                                                                             Composition (percent by weight)                                                                    Tg α                                                                              Crystal-                                     glass                                                                               PbO  ZnO B.sub.2 O.sub.3                                                                   SiO.sub.2                                                                          TiO.sub.2                                                                          (°C.)                                                                      (10.sup.-7 /°C.)                                                              linity                                       __________________________________________________________________________      G401*                                                                              40   25   5 10  20  360                                                                               58    ◯                                G402 50   25   5 10  10  363                                                                               68    ◯                                G403 75   10   5  5  5   344                                                                               87    ◯                                 G404*                                                                              85   10   5  0  0   315                                                                               96    X                                             G405*                                                                              55   40   5  0  0   350                                                                               60    ◯                                G406 55   30  10  0  5   361                                                                               66    ◯                                G407 70    5  15  5  5   375                                                                               82    ◯                                 G408*                                                                              70    0  20  5  5   396                                                                               85    X                                            G409   67.5                                                                              20  10  0    2.5                                                                              382                                                                               83    ◯                                G410   67.4                                                                              20  10   0.1                                                                                2.5                                                                              385                                                                               84    ◯                                G411   62.5                                                                              20  10  5    2.5                                                                              392                                                                               78    ◯                                G412   57.5                                                                              20  10 10    2.5                                                                              401                                                                               75    ◯                                 G413*                                                                                47.5                                                                              20  10 20    2.5                                                                              405                                                                               70    ◯                                 G414*                                                                                59.9                                                                              20  10 10    0.1                                                                              392                                                                               71    ◯                                G415   59.5                                                                              20  10 10    0.5                                                                              400                                                                               73    ◯                                G416 55   20  10 10  5   404                                                                               69    ◯                                G417 50   20  10 10  10  408                                                                               68    ◯                                 G418*                                                                              45   20  10 10  15  420                                                                               65    ◯                                __________________________________________________________________________      A mark "*" denotes a control sample which is not within the scope of the       present invention.                                                       

As shown in Table 13, the addition of a large amount of PbO raises the coefficient of linear expansion (α), while the addition of a large amount of ZnO lowers the glass transition point (Tg), which facilitates crystallization of the glass composition. Conversely, the addition of a large amount of B₂ O₃ raises the glass transition point, and the addition of more than 15.0 percent by weight of B₂ O₃ causes difficulty in crystallization of the glass composition. Further, with an increase in the amount of SiO₂ added, the glass transition point tends to increase, while the coefficient of linear expansion tends to decrease. With an increase in the amount of TiO₂ added, the crystallization of glass proceeded. The glass composition comprising a small amount of PbO and B₂ O₃ tended to become porous.

Next, the aforesaid frit glass was made into paste, after which the resulting glass paste was applied to the sides of the sintered body of Example 1, followed by baking treatment to prepare a sample of a zinc oxide varistor in the same process as that used in Example 1 above. Thereafter, the resulting samples were evaluated for their characteristics. The results are shown in Table 14 below.

                                      TABLE 14                                     __________________________________________________________________________                          Life under                                                                           Discharge withstand current                         Name of              voltage                                                                              rating properties                                   glass  Appearance                                                                            V.sub.1 mA /V.sub.10 μA                                                            (Time)                                                                               40 kA                                                                              50 kA                                                                              60 kA                                                                              70 kA                                                                              80 kA                               __________________________________________________________________________      G401* Peel off                                                                              1.16   480   X   --  --  --  --                                  G402   Good   1.21   420   ◯                                                                      ◯                                                                      Δ                                                                            X   --                                  G403   Good   1.32   331   ◯                                                                      ◯                                                                      Δ                                                                            X   --                                   G404* Crack  1.55    15   X   --  --  --  --                                   G405* Partially                                                                             1.31   181   Δ                                                                            X   --  --  --                                         Peel off                                                                G406   Good   1.24   295   ◯                                                                      ◯                                                                      ◯                                                                      ◯                                                                      X                                   G407   Good   1.20   316   ◯                                                                      ◯                                                                      X   --  --                                   G408* Partially                                                                             1.35   202   X   --  --  --  --                                         crack                                                                   G409   Good   1.25   367   ◯                                                                      Δ                                                                            X   --  --                                  G410   Good   1.26   351   ◯                                                                      ◯                                                                      Δ                                                                            X   --                                  G411   Good   1.25   410   ◯                                                                      ◯                                                                      ◯                                                                      X   --                                  G412   Good   1.20   530   ◯                                                                      ◯                                                                      X   --  --                                   G413* Porous 1.19   366   ◯                                                                      X   --  --  --                                   G414* Good   1.34   197   ◯                                                                      X   --  --  --                                  G415   Good   1.29   348   ◯                                                                      ◯                                                                      Δ                                                                            X   --                                  G416   Good   1.17   435   ◯                                                                      ◯                                                                      ◯                                                                      ◯                                                                      X                                   G417   Good   1.15   650   ◯                                                                      ◯                                                                      Δ                                                                            X   --                                   G418* Porous 1.20   241   Δ                                                                            X   --  --  --                                  Conventional                                                                          Good   1.26   153   ◯                                                                      Δ                                                                            X   --  --                                  example                                                                        __________________________________________________________________________      A mark "*" denotes a control sample which is not within the scope of the       present invention.                                                       

The data shown in Tables 13 and 14 indicated that when the coefficient of linear expansion of glass for coating was smaller than 65×10⁻⁷ /°C. (G401, G405 glass), the glass tended to peel off, and when exceeding 90×10⁻⁷ /°C. (G404 glass), the glass tended to crack. It is supposed that the samples of glass which cracked or peeled off have poor discharge withstand current rating properties due to the inferior insulating properties of the high resistive side layer. However, even if the coefficient of linear expansion of glass for coating is within the range of 65×10⁻⁷ to 90×10⁻⁷ /°C., glass with poor crystallinity (G408 glass) tends to crack and also has poor discharge withstand current rating properties. This may be attributed to the fact that the coating film of crystallized glass has higher strength than that of noncrystal glass.

The amount of TiO₂ added will now be considered. First, any composition with 0.5 percent by weight or more of TiO₂ added has the improved nonlinearity with respect to voltage, accompanied by the improved life characteristics under voltage. This may be attributed to the fact that the addition of 0.5 percent by weight or more of TiO₂ raises the insulation resistance of the coating film. On the other hand, the addition of more than 10.0 percent by weight of TiO₂ lowers the discharge withstand current rating properties. This may be attributed to the fact that glass tends to become porous due to its poor fluidity during the baking process. Consequently, a PbO--ZnO--B₂ O₃ --SiO₂ --TiO₂ type crystallized glass composition for the high resistive side layer of a zinc oxide varistor is required to comprise TiO₂ at least in an amount of 0.5 to 10.0 percent by weight.

The above results confirmed that the most preferable crystallized glass composition for coating comprised 50.0 to 75.0 percent by weight of PbO, 10.0 to 30.0 percent by weight of ZnO, 5.0 to 10.0 percent by weight of B₂ O₃, 0 to 15.0 percent by weight of SiO₂, and 0.5 to 10.0 percent by weight of TiO₂. A crystallized glass composition for the high resistive side layer of a zinc oxide varistor is also required to have coefficients of linear expansion in the range of 65×10⁻⁷ to 90×10⁻⁷ /°C.

Next, by the use of G406 glass shown as a sample of the present invention in Table 13, the amount of glass paste to be applied was examined. The results are shown in Table 15 below. Glass paste was applied in a ratio of 1.0 to 300.0 mg/cm², which was controlled by the viscosity and the number of application of the paste. As shown in Table 15, when glass paste is applied in a ratio of less than 10.0 mg/cm² the resulting coating film has low strength, while with a ratio of more than 150.0 mg/cm² glass tends to flow or have pinholes. Both cases result in poor discharge withstand current rating properties. These results indicated that glass paste was applied most preferably in a ratio of 10.0 to 150.0 mg/cm².

                                      TABLE 15                                     __________________________________________________________________________         Amount of           Life under                                                                           Discharge withstand current                      Sample                                                                             application         voltage                                                                              rating properties                                No. (mg/cm.sup.2)                                                                        Appearance                                                                            V.sub.1 mA /V.sub.10 μA                                                            (Time)                                                                               40 kA                                                                              50 kA                                                                              60 kA                                                                              70 kA                                                                              80 kA                            __________________________________________________________________________     401*                                                                                1    Good   1.11   314   X   --  --  --  --                               402*                                                                                5    Good   1.14   380   Δ                                                                            X   --  --  --                               403 10    Good   1.16   560   ◯                                                                      ◯                                                                      Δ                                                                            X   --                               404 50    Good   1.17   435   ◯                                                                      ◯                                                                      ◯                                                                      ◯                                                                      X                                405 150   Good   1.25   413   ◯                                                                      ◯                                                                      ◯                                                                      ◯                                                                      X                                406*                                                                               200   Partially                                                                             1.29   242   ◯                                                                      X   --  --  --                                         flow                                                                 407*                                                                               300   Flow   1.36   191   Δ                                                                            X   --  --  --                               __________________________________________________________________________      A mark "*" denotes a control sample which is not within the scope of the       present invention.                                                       

Next, by the use of G406 glass shown as a sample of the present invention in Table 13, the conditions under which glass paste was subjected to baking treatment were examined. The results are shown in Table 16 below. The viscosity and the number of application of glass paste were controlled so that the glass paste may be applied in a ratio of 50.0 mg/cm². Glass paste was subjected to baking treatment at temperatures in the range of 350° to 700° C. for 1 hour in air. As a result, when baking treatment was conducted at a temperature of less than 450° C., glass paste was not sufficiently melted, resulting in poor discharge withstand current rating properties. On the other hand, when baking treatment was conducted at a temperature of more than 600° C., the voltage ratio markedly lowered, resulting in poor life characteristics under voltage. These results indicated that glass paste was subjected to baking treatment most preferably at temperatures in the range of 450° to 600° C.

                                      TABLE 16                                     __________________________________________________________________________         Temperature          Life under                                                                           Discharge withstand current                     Sample                                                                             of baking            voltage                                                                              rating properties                               No. (°C.)                                                                          Appearance                                                                            V.sub.1 mA /V.sub.10 μA                                                            (Time)                                                                               40 kA                                                                              50 kA                                                                              60 kA                                                                              70 kA                                                                              80 kA                           __________________________________________________________________________     411*                                                                               350    Not    1.10    45   X   --  --  --  --                                         sintered                                                            412*                                                                               400    Porous 1.13    40   Δ                                                                            X   --  --  --                              413 450    Good   1.15   241   ◯                                                                      ◯                                                                      X   --  --                              414 500    Good   1.16   492   ◯                                                                      ◯                                                                      ◯                                                                      X   --                              415 600    Good   1.23   650   ◯                                                                      ◯                                                                      ◯                                                                      ◯                                                                      --                              416*                                                                               650    Partially                                                                             1.34   206   ◯                                                                      X   --  --  --                                         flow                                                                417*                                                                               700    Partially                                                                             1.58    13   Δ                                                                            X   --  --  --                                         flow                                                                __________________________________________________________________________      A mark "*" denotes a control sample which is not within the scope of the       present invention.                                                       

EXAMPLE 5

Crystallized glass comprising PbO as a main component which contains NiO, and a zinc oxide varistor using the same as a material constituting a high resistive side layer will now be explained.

First, each predetermined amount of PbO, ZnO, B₂ O₃, SiO₂, and NiO was weighed, and then crystallized glass for coating was prepared according to the same process as that used in Example 1 above. The crystallized glass thus obtained was evaluated for the glass transition point (Tg), the coefficient of linear expansion (α), and the crystallinity. The results are shown in Table 17 below.

                                      TABLE 17                                     __________________________________________________________________________     Name of                                                                             Composition (percent by weight)                                                                    Tg α                                                                              Crystal-                                     glass                                                                               PbO  ZnO B.sub.2 O.sub.3                                                                   SiO.sub.2                                                                          NiO (°C.)                                                                      (10.sup.-7 /°C.)                                                              linity                                       __________________________________________________________________________      G501*                                                                              50   25   5 10  10  354                                                                               59    ◯                                G502 55   25   5 10  5   360                                                                               69    ◯                                G503 75   10   5  5  5   346                                                                               88    ◯                                G504 85   10   5  0  0   315                                                                               96    X                                             G505*                                                                              55   40   5  0  0   350                                                                               60    ◯                                G506 55   30  10  0  5   359                                                                               68    ◯                                G507 70    5  15  5  5   370                                                                               84    Δ                                       G508*                                                                              70    0  20  5  5   394                                                                               88    X                                            G509   67.5                                                                              20  10  0    2.5                                                                              380                                                                               85    ◯                                G510   67.4                                                                              20  10   0.1                                                                                2.5                                                                              381                                                                               85    ◯                                G511   62.5                                                                              20  10  5    2.5                                                                              393                                                                               78    ◯                                G512   57.5                                                                              20  10 10    2.5                                                                              404                                                                               76    ◯                                 G513*                                                                                47.5                                                                              20  10 20    2.5                                                                              409                                                                               71    ◯                                G514   59.9                                                                              20  10 10    0.1                                                                              393                                                                               72    ◯                                G515   59.5                                                                              20  10 10    0.5                                                                              395                                                                               72    ◯                                G516 57   20  10 10    2.5                                                                              405                                                                               70    ◯                                G517 55   20  10 10  5   406                                                                               69    ◯                                 G518*                                                                              50   20  10 10  10  415                                                                               63    ◯                                __________________________________________________________________________      A mark "*" denotes a control sample which is not within the scope of the       present invention.                                                       

As shown in Table 17, the addition of a large amount of PbO raises the coefficient of linear expansion (α), while the addition of a large amount of ZnO lowers the glass transition point (Tg), which facilitates crystallization of the glass composition. Conversely, the addition of a large amount of B₂ O₃ raises the glass transition point, end the addition of more than 15.0 percent by weight of B₂ O₃ causes difficulty in crystallization of the glass composition. Further, with an increase in the Mount of SiO₂ added, the glass transition point tends to increase, while the coefficient of linear expansion tends to decrease. With an increase in the amount of NiO added, the crystallization of glass proceeded. The glass composition comprising a small amount of PbO and B₂ O₃ tended to become porous.

Next, the aforesaid frit glass was made into paste, after which the resulting glass paste was applied to the sides of the sintered body of Example 1, followed by baking treatment to prepare a sample of a zinc oxide varistor in the same process as that used in Example 1 above. Thereafter, the resulting samples were evaluated for their characteristics. The results are shown in Table 18 below.

                                      TABLE 18                                     __________________________________________________________________________                          Life under                                                                           Discharge withstand current                         Name of              voltage                                                                              rating properties                                   glass  Appearance                                                                            V.sub.1 mA /V.sub.10 μA                                                            (Time)                                                                               40 kA                                                                              50 kA                                                                              60 kA                                                                              70 kA                                                                              80 kA                               __________________________________________________________________________      G501* Peel off                                                                              1.15   490   X   --  --  --  --                                  G502   Good   1.20   440   ◯                                                                      ◯                                                                      Δ                                                                            X   --                                  G503   Good   1.33   331   ◯                                                                      ◯                                                                      Δ                                                                            X   --                                   G504* Crack  1.55    15   X   --  --  --  --                                   G505* Partially                                                                             1.31   181   Δ                                                                            X   --  --  --                                         peel off                                                                G506   Good   1.25   288   ◯                                                                      ◯                                                                      ◯                                                                      ◯                                                                      X                                   G507   Good   1.22   340   ◯                                                                      ◯                                                                      Δ                                                                            X   --                                   G508* Partially                                                                             1.34   207   X   --  --  --  --                                         crack                                                                   G509   Good   1.25   335   ◯                                                                      Δ                                                                            X   --  --                                  G510   Good   1.28   384   ◯                                                                      ◯                                                                      ◯                                                                      X   --                                  G511   Good   1.27   411   ◯                                                                      ◯                                                                      ◯                                                                      X   --                                  G512   Good   1.24   492   ◯                                                                      ◯                                                                      X   --  --                                   G513* Porous 1.18   375   Δ                                                                            X   --  --  --                                   G514* Good   1.33   209   ◯                                                                      X   --  --  --                                  G515   Good   1.29   394   ◯                                                                      ◯                                                                      Δ                                                                            X   --                                  G516   Good   1.18   482   ◯                                                                      ◯                                                                      ◯                                                                      ◯                                                                      Δ                             G517   Good   1.16   591   ◯                                                                      ◯                                                                      ◯                                                                      Δ                                                                            X                                    G518* Porous 1.23   205   Δ                                                                            X   --  --  --                                  Conventional                                                                          Good   1.26   153   ◯                                                                      Δ                                                                            X   --  --                                  example                                                                        __________________________________________________________________________      A mark "*" denotes a control sample which is not within the scope of the       present invention.                                                       

The data shown in Tables 17 and 18 indicated that when the coefficient of linear expansion of glass for coating was smaller than 65×10⁻⁷ /°C. (G501, G505 glass), the glass tended to peel off, and when exceeding 90×10⁻⁷ /°C (G504 glass), the glass tended to crack. It is supposed that the samples of glass which cracked or peeled off have poor discharge withstand current rating properties due to the inferior insulating properties of the high resistive side layer. However, even if the coefficient of linear expansion of glass for coating is within the range of 65×10⁻⁷ to 90×10⁻⁷ /°C., glass with poor crystallinity (G508 glass) tends to crack and also has poor discharge withstand current rating properties. This may be attributed to the fact that the coating film of crystallized glass has higher strength than that of noncrystal glass.

The amount of NiO added will now be considered. First, any composition with 0.5 percent by weight or more of NiO added has the improved non-linearity with respect to voltage, accompanied by the improved life characteristics under voltage. This may be attributed to the fact that the addition of 0.5 percent by weight or more of NiO raises the insulation resistance of the coating film. On the other hand, the addition of more than 5.0 percent by weight of NiO lowers the discharge withstand current rating properties. This may be attributed to the fact that glass tends to become porous due to its poor fluidity during baking process. Consequently, a PbO--ZnO--B₂ O₃ --SiO₂ --NiO type crystallized glass composition for the high resistive side layer of a zinc oxide varistor is required to comprise NiO at least in an amount of 0.5 to 5.0 percent by weight.

The above results confirmed that the most preferable crystallized glass composition for coating comprised 55.0 to 75.0 percent by weight of PbO, 10.0 to 30.0 percent by weight of ZnO, 5.0 to 10.0 percent by weight of B₂ O₃, 0 to 15.0 percent by weight of SiO₂, and 0.5 to 5.0 percent by weight of NiO. A crystallized glass composition for the high resistive side layer of a zinc oxide varistor is also required to have coefficients of linear expansion in the range of 65×10⁻⁷ to 90×10⁻⁷ /°C.

Next, by the use of G516 glass shown as a sample of the present invention in Table 17, the amount of glass paste to be applied was examined. The results are shown in Table 19 below. Glass paste was applied in a ratio of 1.0 to 300.0 mg/cm² which was controlled by the viscosity and the number of application of paste. In this process when glass paste is applied in a ratio of less than 10.0 mg/cm² the resulting coating film has low strength, while with a ratio of more than 150.0 mg/cm² glass tends to flow or have pinholes. Both cases result in poor discharge withstand current rating properties. These results indicated that glass paste was applied most preferably in a ratio of 10.0 to 15.0 mg/cm².

                                      TABLE 19                                     __________________________________________________________________________         Amount of           Life under                                                                           Discharge withstand current                      Sample                                                                             application         voltage                                                                              rating properties                                No. (mg/cm.sup.2)                                                                        Appearance                                                                            V.sub.1 mA /V.sub.10 μA                                                            (Time)                                                                               40 kA                                                                              50 kA                                                                              60 kA                                                                              70 kA                                                                              80 kA                            __________________________________________________________________________      501*                                                                               1    Good   1.12   300   X   --  --  --  --                               502  5    Good   1.14   391   ◯                                                                      X   --  --  --                               503 10    Good   1.17   567   ◯                                                                      ◯                                                                      ◯                                                                      X   --                               504 50    Good   1.18   482   ◯                                                                      ◯                                                                      ◯                                                                      ◯                                                                      Δ                          505 150   Good   1.26   318   ◯                                                                      ◯                                                                      ◯                                                                      ◯                                                                      X                                 506*                                                                              200   Partially                                                                             1.29   209   ◯                                                                      X   --  --  --                                         flow                                                                  507*                                                                              300   Flow   1.38   154   Δ                                                                            X   --  --  --                               __________________________________________________________________________      A mark "*" denotes a control sample which is not within the scope of the       present invention.                                                       

Next, by the use of G516 glass shown as a sample of the present invention in Table 17, the conditions under which glass paste was subjected to baking treatment were examined. The results are shown in Table 20 below. The viscosity and the number of application of glass paste were controlled so that the glass paste may be applied in a ratio of 50.0 mg/cm². Glass paste was subjected to baking treatment at temperatures in the range of 350° to 700° C. for 1 hour in air. As a result, when baking treatment was conducted at a temperature of less than 450° C., glass paste was not sufficiently melted, resulting in poor discharge withstand current rating properties. On the other hand, when baking treatment was conducted at a temperature of more than 60° C., the voltage ratio markedly lowered, resulting in poor life characteristics under voltage. These results indicated that glass paste was subjected to baking treatment most preferably at temperatures in the range of 450° to 600° C.

                                      TABLE 20                                     __________________________________________________________________________         Temperature          Life under                                                                           Discharge withstand current                     Sample                                                                             of baking            voltage                                                                              rating properties                               No. (°C.)                                                                          Appearance                                                                            V.sub.1 mA /V.sub.10 μA                                                            (Time)                                                                               40 kA                                                                              50 kA                                                                              60 kA                                                                              70 kA                                                                              80 kA                           __________________________________________________________________________     511*                                                                               350    Not    1.11    40   X   --  --  --  --                                         sintered                                                            512*                                                                               400    Porous 1.14    32   Δ                                                                            X   --  --  --                              513 450    Good   1.14   251   ◯                                                                      ◯                                                                      X   --  --                              514 500    Good   1.17   483   ◯                                                                      ◯                                                                      ◯                                                                      X   --                              515 600    Good   1.25   644   ◯                                                                      ◯                                                                      ◯                                                                      ◯                                                                      X                               516*                                                                               650    Partially                                                                             1.33   217   ◯                                                                      X   --  --  --                                         flow                                                                517*                                                                               700    Partially                                                                             1.54    12   Δ                                                                            X   --  --  --                                         flow                                                                __________________________________________________________________________      A mark "*" denotes a control sample which is not within the scope of the       present invention.                                                       

As typical examples of crystallized glass comprising PbO as a main component, described are four-components type such as PbO--ZnO--B₂ O₃ --SiO₂ in Example 1 above, four-components type such as PbO--ZnO--B₂ O₃ --MoO₃, and five-components type such as PbO--ZnO--B₂ O₃ --SiO₂ --MoO₃ in Example 2, five-components type such as PbO--ZnO--B₂ O₃ --SiO₂ --WO₃ in Example 3, four-components Type such as PbO--ZnO--B₂ O₃ --TiO₂, and five-components type such as PbO--ZnO--B₂ O₃ --SiO₂ --TiO₂ in Example 4, and four-components type such as PbO--ZnO--B₂ O₃ --NiO and five-components type such as PbO--ZnO--B₂ O₃ --SiO₂ --NiO in Example 5. The effect of the present invention may not vary according to the addition of an additive which further facilitates crystallization of glass such as Al₂ O₃ or SnO₂.

As a substance for lowering the glass transition point, ZnO was used in the above examples, and it is needless to say that other substances such as V₂ O₅ which are capable of lowering the glass transition point may also be used as a substitute thereof. Further, as a typical example of an oxide ceramic, crystallized glass for coating comprising PbO as a main component of the present invention is used for a zinc oxide varistor in the examples of the present invention. This crystallized glass may be applied quite similarly to any oxide ceramics employed for a strontium titanate type varistor, a barium Titanate type capacitor, a PTC thermistor, or a metallic oxide type NTC thermistor.

Industrial Applicability

As indicated above, the present invention can provide a zinc oxide varistor excellent in the nonlinearity with respect to voltage, the discharge withstand current rating properties, and the life characteristics under voltage by using various PbO type crystallized glass with high crystallinity and strong coating film as a material constituting the high resistive side layer formed on a sintered body comprising zinc oxide as a main component. A zinc oxide varistor of the present invention has very high availability as a characteristic element of an arrestor for protecting a transmission and distribution line and peripheral devices thereof requiring high reliability from surge voltage created by lightning.

Crystallized glass for coating comprising PbO as a main component of the present invention may be used as a covering material for not only a zinc oxide varistor but also various oxide ceramics employed for a strontium titanate type varistor, a barium titanate type capacitor, a positive thermistor, etc., and a metallic oxide type negative thermistor and a resistor to enhance the strength and stabilize or improve the various electric characteristics thereof. Moreover, apparent from above examples, conventional glass for coating tends to have a porous structure because it is composite glass containing feldspar, whereas the PbO type crystallized glass of the present invention is also capable of improving the chemical resistance and the moisture resistance due to the high crystallinity end the tendency to have a uniform end close structure, thereby promising many very useful applications. 

I claim:
 1. A crystallized glass composition for coating a zinc oxide varistor having varistor characteristics, the composition consisting of 50.0 to 64 percent by weight of PbO, 25 to 30.0 percent by weight of ZnO, 5.0 to 10.0 percent by weight of B₂ O₃, and 6.0 to 15.0 percent by weight of SiO₂.
 2. The crystallized glass composition according to claim 1, having a coefficient of linear expansion in the range of 65×10⁻⁷ to 90×10⁻⁷ /°C.
 3. The crystallized glass composition according to claim 1 consisting of 60 percent by weight of PbO, 29 percent by weight of ZnO, 5 percent by weight of B₂ O₃, and 6 percent by weight of SiO₂.
 4. The crystallized glass composition according to claim 1 consisting of 62.5 percent by weight of PbO, 25 percent by weight of ZnO, 5 percent by weight of B₂ O₃, and 7.5 percent by weight of SiO₂.
 5. A crystallized glass composition for coating a zinc oxide varistor having varistor characteristics, the composition consisting of 50.0 to 70 percent by weight of PbO, 20 to 30.0 percent by weight of ZnO, 5.0 to 15 percent by weight of B₂ O₃, 0 to 15.0 percent by weight of SiO₂, and 0.1 to 10.0 percent by weight of MoO₃.
 6. The crystallized glass composition according to claim 5 having a coefficient of linear expansion in the range of 65×10⁻⁷ to 90×10⁻⁷ /°C.
 7. A crystallized glass composition for coating a zinc oxide varistor having varistor characteristics, the composition consisting of 50.0 to 55 percent by weight of PbO, 20 to 30.0 percent by weight of ZnO, 5.0 to 10.0 percent by weight of B₂ O₃, 5 to 15.0 percent be weight of SiO₂, and 5 to 10.0 percent by weight MoO₃.
 8. A crystallized glass composition for coating a zinc oxide varistor having varistor characteristics, the composition consisting of 50 percent by weight of PbO, 25 percent by weight of ZnO, 5 percent by weight of B₂ O₃, 10 percent by weight of SiO₂, and 10 percent by weight of MoO₃.
 9. A crystallized glass composition for coating a zinc oxide varistor having varistor characteristics, the composition consisting of 50 percent by weight of PbO, 20 percent by weight of ZnO, 10 percent by weight of B₂ O₃, 10 percent by weight of SiO₂, and 10 percent by weight of MoO₃.
 10. A crystallized glass composition for coating a zinc oxide varistor having varistor characteristics, the composition consisting of 50.0 to 70 percent by weight of PbO, 20 to 30.0 percent by weight of ZnO, 5.0 to 15.0 percent by weight of B₂ O₃, 0.5 to 15.0 percent by weight of SiO₂, and 0.1 to 10.0 percent by weight of WO₃.
 11. The crystallized glass composition according to claim 10 having a coefficient of linear expansion in the range of 65×10⁻⁷ to 90×10⁻⁷ /° C.
 12. A crystallized glass composition for coating a zinc oxide varistor having varistor characteristics, the composition consisting of 50.0 to 55 percent by weight of PbO, 20 to 30.0 percent by weight of ZnO, 5.0 to 10 percent by weight of B₂ O₃, 5 to 15.0 percent by weight of SiO₂, and 5 to 10.0 percent by weight of WO₃.
 13. A crystallized glass composition for coating a zinc oxide varistor having varistor characteristics, the composition consisting of 50 percent by weight of PbO, 20 percent by weight of ZnO, 10 percent by weight of B₂ O₃, 10 percent by weight of SiO₂, and 10 percent by weight of WO₃.
 14. A crystallized glass composition for coating a zinc oxide varistor having varistor characteristics, the composition consisting of 50.0 to 55 percent by weight of PbO, 10.0 to 30.0 percent by weight of ZnO, 5.0 to 15.0 percent by weight of B₂ O₃, 0 to 15.0 percent by weight of SiO₂, and 0.5 to 10.0 percent by weight of TiO₂.
 15. A crystallized glass composition for coating a zinc oxide varistor having varistor characteristics, the composition consisting of 50.0 to 75.0 percent by weight of PbO, 25 to 30.0 percent by weight of ZnO, 5.0 to 15.0 percent by weight of B₂ O₃, 0 to 15.0 percent by weight of SiO₂, and 0.5 to 10.0 percent by weight of TiO₂.
 16. A crystallized glass composition for coating a zinc oxide varistor having varistor characteristics, the composition consisting of 50.0 to 75.0 percent by weight of PbO, 10.0 to 30.0 percent by weight of ZnO, 5.0 to 15.0 percent by weight of B₂ O₃, 0 to 0.1 percent by weight of SiO₂, and 0.5 to 10.0 percent by weight of TiO₂.
 17. A crystallized glass composition for coating a zinc oxide varistor having varistor characteristics, the composition consisting of 50.0 to 75.0 percent by weight of PbO, 10.0 to 30.0 percent by weight of ZnO, 5.0 to 15.0 percent by weight of B₂ O₃, 0 to 15.0 percent by weight of SiO₂, and 0.5 to 2.5 percent by weight of TiO₂. 